SPARE PART POOL PROGAM Suparno PT Pembangkitan Jawa Bali Sumatera Kalimantan 2006 2010 Sales (TWh) 3.8 4,5 7,1 No.of Cust. (M) 1.8 2 3.8 6,0 Capacity (GW) 0,7 1,3 56.9 61,9 Electrif Ratio (%) 58.7 52,9 2006 2010 Sales (TWh) 14.6 16,3 No.of Cust. (M) 6.6 Capacity (GW) Electrif Ratio (%) Sulawesi 2006 2010 Sales (TWh) 3.6 4,4 No.of Cust. (M) 2.1 2,6 Capacity (GW) 0.9 1,3 Electrif Ratio (%) 57.2 53,8 Others Jawa-Bali 2006 2010 2006 2010 Sales (TWh) 3.7 5,3 87 125,9 No.of Cust. (M) 1.8 2,1 No.of Cust. (M) 23.4 27,3 Capacity (GW) 0.6 1,1 Capacity (GW) 3/18/2016 18,6 28,3 Electrif Ratio 40.2 37,9 Electrif Ratio 63.5 69,4 Sales (TWh) 2 PLN Organisation PLN (HOLDING) PLN Region/Distribution BU PLN Dispatching Center BU PLN Training Centre BU Subsidiary : - Indonesia Power - PJB (Java Bali) - PLN Engineering - PLN Batam - PLN Tarakan PJB Highlight 2008 • EXISTING : – Installed Capacity : 6,491 MW – Sales : 30 TWh – Market Share (Java) : 26 % – No. of Employees : 2,200 • JVC : – Cilacap SPP (Coal) : 2 x 300 MW – Asahan HEPP : 2 x 90 MW – Gunung Megang GT : 2 x 40 MW PJB Power Plant MUARA KARANG SPP (OIL) : 300 MW SPP (Nat. Gas) : 400 MW CCPP (Nat. Gas) : 508 MW MUARA TAWAR CCPP (OIL/Nat. Gas) : 920 MW Jakarta GRESIK SPP (Nat. Gas) : 600 MW GT : 101 MW CCPP (Nat. Gas) : 1,579 MW MADURA JAVA WEST CENTRAL BALI EAST T.DUKU GT : 35 MW CIRATA HEPP : 1,008 MW INSTALLED CAP. PJB : 6,491 MW BRANTAS HEPP : 275 MW PAITON SPP (Coal) : 800 MW Power Plant Governance PJB PERFORMANCE KINERJA Finance Prod.Cost Keuangan : Pendapatan Revenue and, Biaya Produksi Operation Operasi : EAF, EFOR, EFOR, Efisiensi Efisiensi Performance Management BSC Maturity Level GENERATION PLAN Assesment Lead & Lag Programe and Performance indicator Continuous Improvement Manajemen Risk Management Risiko Reliability Improvement Management WPC Optimasi Management WPC Outage Management Continous Improvement : Continuous Improvement Material Supply Chain Management Management Efficiency Efficiency Management Management SMM, SMM, SMT( SML, SMK3 SMK3) Information People Management & Work Culture System People & Work Culture People & Work Culture Operation EAMS & ME Management - Physical Asset - Knowledge Asset - Human Asset Power Plant Performance • Availability • Reliability • Thermal Effisiency PJB • Strategic Spares Policy • MOU PJB – IP- PG BU PLN • List Of Strategic spares Material Mgt. Support • Service Level – Time – Quality – Quantity – Price HAPUA PP Community • Objective : – Spare Part Pool Program – Sharing Information • • • • • • Data share (Machine, Equipment , Spare Part) Supplier (Manufacture, Vendor, Distributor , Agent) Price List OEM vs Non OEM LTSA E- Commercial – Sharing Policy Constraint • • • • • • Tax Policy Exim Policy Corporate Policy Accounting Policy Transportation Government Regulation Material Mgt Governance PJB PERFORMANCE Service Level, Purchase Effectiveness, Inventory Level, Turn Over Maturity Level Continuous KPI Process Assesment Lead & Lag Programe and Performance indicator Improvement Procedure and Policy Requirement Management Inventory Management Warehouse Management Purchasing Management Supplier Management Continous Improvement : Information Management System People and Work Culture - Physical Asset Continuous - Knowledge Asset Improvement - Human Asset MATERIAL Mgt BUSSINES PROCESS GOAL SERVICE LEVEL MATERIAL MANAGAMENT TIME MATERIAL DEMAND QUALITY INVENTORY LEVEL For“Receiving” Inventory Level On Schedule On Quality On Quantity On Cost QUANTITY PLANING & CONTROLING “REQUIREMENT” What ? How ? When ? Who ? Inventory Policy PLANING & CONTROLING “INVENTORY” Outage Management Recomended Order What Order ? How many Order ? When Order? Supplier Management PLANING & CONTROLING “PROCUREMENT” Issue Strategic Spares OPERATION & MAINTENANCE UNIT Service MATERIAL REQUIREMENT ROUTINE PERIODIC REQ. IDENTIFY CORRECTIVE OVERHAUL PREVENTIVE PROJECT • INVENTORY POLICY • STRATEGIC SPARE REQ. PLANNING • OUTAGE MANAGEMENT • APLICATION PART LIST (APL) ROP & ROQ INVENTORY PLANNING JIT PROCUREMENT PLANNING • LTSA • NON LTSA • INDIVIDUAL STOCK • ALIANCE STOCK • CONSIMENT STOCK STOCK METODE Material Mgt Organisation PJB BOD Approval Authority HEAD OFFICE OWN PRICE ESTIMATE INVENTORY CONTROLER CORPORATE PROCUREMENT Process Authority POWER PLANT CATALOGER PROCUREMENT INVENTORY CONTROLER OWN PRICE ESTIMATE WAREHOUSING THANK YOU Iventory Policy PJB Material Identify based in ABC Analisys (Criticality, Availbility , Usage value) Inventory Control Treatment Purchasing Treatment Identify based on Requirement • Warehouse Stock • ROP & ROQ • Min & Max • Consignment Stock • Just In Time • LTSA Optimal item Stock and Value Optimal Service Level Strategic Spares PJB Maintenance Priority Index (MPI ) Equipment Level Coorporate Policy Condition factor 1. Unit influen 2. Demage Pola 3. Need Pola 4. Assembly quantity 5. Changeable methode 6. Lead time to work/change part 7. Unit price 8. Delivery time Strategic Spares Part Level ABC Analysis Outage Management PJB Frame Work Outage Mgt. : PRE OUTAGE OUTAGE EXECUTION PLANNING 18 bln POST OUTAGE PREPARATION 12 bln 6 bln 3 bln 1 bln 1 Mng 0 bln OH R1 R2 ( Skope, Anggaran, ( Skope, Anggaran, Sparepart Utama ) Sparepart Utama ) R3 ( Skope, Anggaran, Sparepart Pendukung ) P1 , P2 , P3 ( Skope, Anggaran, Sparepart Umum ) FEED BACK ( Input next Inspection ) OH Application Part List (APL) PJB Store and Inventory Supply Catalog Searching Methods Searching Methods Application Part List Equip Ref Equip Group ID Component Code Modifier Code Sequence No Maint Sched Task Standard Job Task Work Order Task Component Component Component Scope Of Work - Major or Serious Inspection Turbine or Mean Inspection Combustion or Simple Inspection 6 Monthly 3 Monthly Monthly 2 Weekly Etc Equip Group ID Group Equipment Equip Register Equipment WORK FLOW MATERIAL MANAJEMENT PJB MUARA KARANG POWER PLANT No. Unit Turbine Merk Operation RPM Year Merk Generator Capicity Volt MVA Cos Q MW SPP 1 MITSUBHISHI 3000 1979 MITSUBHISHI 11500 125.00 0.8 100.00 SPP 2 MITSUBHISHI 3000 1979 MITSUBHISHI 11500 125.00 0.8 100.00 SPP 3 MITSUBHISHI 3000 1979 MITSUBHISHI 11500 125.00 0.8 100.00 SPP 4 MITSUBHISHI 3000 1981 MITSUBHISHI 18000 250.00 0.8 200.00 SPP 5 MITSUBHISHI 3000 1982 MITSUBHISHI 18000 250.00 0.8 200.00 GT 1.1 GE 3000 1992 GE 11500 142.00 0.8 107.86 GT 1.2 GE 3000 1992 GE 11500 142.00 0.8 107.86 GT 1.3 GE 3000 1992 GE 11500 142.00 0.8 107.86 ST1.0 GE 3000 1995 GE 11500 237.50 0.8 185.00 MUARA TAWAR POWER PLANT No. Turbine Unit Merk GT 1.1 ABB GT 1.2 RPM Operation Generator Capacity Years Merk Volt MVA Cos Q MW 3000 1997 ABB 16000 182,70 0,8 145,00 ABB 3000 1997 ABB 16000 182,70 0,8 145,00 GT 1.3 ABB 3000 1997 ABB 16000 182,70 0,8 145,00 ST1.0 ABB 3000 1997 ABB 16000 182,70 0,8 225,00 GT 2.1 ABB 3000 1997 ABB 16000 182,70 0,8 145,00 GT 2.2 ABB 3000 1997 ABB 16000 182,70 0,8 145,00 GRESIK POWER PLANT No. Turbine Unit Merk SPP 1 TOSHIBA SPP 2 RPM Operatin Generator Capacity Yaer Merk Volt MVA Cos Q MW 3000 1981 TOSHIBA 13200 125.00 0.8 100.00 TOSHIBA 3000 1981 TOSHIBA 13200 125.00 0.8 100.00 SPP 3 TOSHIBA 3000 1988 TOSHIBA 15000 250.00 0.8 200.00 SPP 4 TOSHIBA 3000 1988 TOSHIBA 15000 250.00 0.8 200.00 GT 1 ALSTHOM 5100 1978 ALSTHOM 11000 25.13 0.8 20.10 GT 2 ALSTHOM 5100 1978 ALSTHOM 11000 25.13 0.8 20.10 GT 4 GE 5100 1993 GE 11500 30.40 0.67 20.10 GT 5 GE 5100 1993 GE 11500 30.40 0.67 20.10 GT 1.1 MITSUBHISHI 3000 1992 SIEMENS 10500 153.75 0.8 112.45 GT 1.2 MITSUBHISHI 3000 1992 SIEMENS 10500 153.75 0.8 112.45 GT 1.3 MITSUBHISHI 3000 1992 SIEMENS 10500 153.75 0.8 112.45 ST1.0 MITSUBHISHI 3000 1993 SIEMENS 15750 251.75 0.8 188.91 GT 2.1 MITSUBHISHI 3000 1992 SIEMENS 10500 153.75 0.8 112.45 GT 2.2 MITSUBHISHI 3000 1992 SIEMENS 10500 153.75 0.8 112.45 GT 2.3 MITSUBHISHI 3000 1992 SIEMENS 10500 153.75 0.8 112.45 ST 2.0 MITSUBHISHI 3000 1993 SIEMENS 15750 251.75 0.8 188.91 GT 3.1 MITSUBHISHI 3000 1993 SIEMENS 10500 153.75 0.8 112.45 GT 3.2 MITSUBHISHI 3000 1993 SIEMENS 10500 153.75 0.8 112.45 GT 3.3 MITSUBHISHI 3000 1993 SIEMENS 10500 153.75 0.8 112.45 ST 3.0 MITSUBHISHI 3000 1993 SIEMENS 15750 251.75 0.8 188.91 BRANTAS POWER PLANT UNIT No. Turbine Unit Merk 1 TOSHIBA 2 RPM Operation Generator Capacity Year Merk Volt MVA Cos Q MW 250 1973 TOSHIBA 11000 39 0,9 35,00 TOSHIBA 250 1973 TOSHIBA 11000 39 0,9 35,00 3 TOSHIBA 250 1974 TOSHIBA 11000 39 0,9 35,00 1 TOSHIBA 143 1978 MEIDENSHA 11000 30 0,9 27,00 2 TOSHIBA 143 1980 MEIDENSHA 11000 30 0,9 27,00 LODOYO HEPP 1 TOSHIBA 150 1983 MEIDENSHA 6600 5,3 0,85 4,50 SENGGURUH 1 BOVING 176,5 1988 ELIN 11000 16,2 0,9 14,50 HEPP 2 BOVING 176,5 1988 ELIN 11000 16,2 0,9 14,50 TULUNG AGUNG 1 VOEST ALPINE MCE 375 1993 ELIN 11000 20 0,9 18,00 HEPP 2 VOEST ALPINE MCE 375 1993 ELIN 11000 20 0,9 18,00 MENDALAN 1 ESCHER WYSS 750 1930 OERLIKON 6000 7 0,8 5,60 HEPP 2 STORK HOLLAND 750 1955 SCHORH 6000 7,25 0,8 5,80 3 STORK HOLLAND 750 1955 SCHORH 6000 7,25 0,8 5,80 4 STORK HOLLAND 750 1955 SCHORH 6000 7,25 0,8 5,80 1 ESCHER WYSS 600 1955 BBC 6000 4,5 0,8 3,6 2 ESCHER WYSS 600 1931 OERLIKON 6000 4,5 0,8 3,6 3 ESCHER WYSS 600 1955 BBC 6000 4,5 0,8 3,6 SELOREJO HEPP 1 EBARA 500 1973 MEIDENSHA 6600 5,6 0,8 4,48 GIRINGAN HEPP 1 STROK HENGELO 1000 1955 SMITH.S. 6300 1,28 0,7 0,90 2 STROK HENGELO 1000 1955 SMITH.S. 6300 1,28 0,7 0,90 3 ESCHER WYSS 1000 1937 HEEMAF 6300 2,00 0,7 1,40 1 NEYRPIC 1000 1959 ALSTHOM 6300 1,28 0,7 0,90 2 NEYRPIC 1000 1959 ALSTHOM 6300 1,28 0,7 0,90 3 NEYRPIC 1000 1959 ALSTHOM 6300 1,28 0,7 0,90 1 B.MAIER 1000 1968 AEG 6300 2,75 0,8 2,20 SUTAMI HEPP WLINGI HEPP SIMAN HEPP GOLANG HEPP NGEBEL HEPP PAITON POWER PLANT UNIT SPP Coal No. Turbine Unit Merk 1 TOSHIBA 3000 1993 TOSHIBA 18000 473.00 0.85 400.00 2 TOSHIBA 3000 1993 TOSHIBA 18000 473.00 0.85 400.00 RPM Operation Generator Capacity Year Merk Volt MVA Cos Q MW CIRATA POWER PLANT No. Turbine Unit Merk HEPP 1 VOEST ALPINE HEPP 2 HEPP UNIT RPM Operation Year Generator Merk Capacity Volt MVA Cos Q MW 187,5 1988 ELIN UNION 16500 140,00 0,90 126,00 VOEST ALPINE 187,5 1988 ELIN UNION 16500 140,00 0,90 126,00 3 VOEST ALPINE 187,5 1988 ELIN UNION 16500 140,00 0,90 126,00 HEPP 4 VOEST ALPINE 187,5 1988 ELIN UNION 16500 140,00 0,90 126,00 HEPP 5 VOEST ALPINE 187,5 1997 ELIN UNION 16500 140,00 0,90 126,00 HEPP 6 VOEST ALPINE 187,5 1997 ELIN UNION 16500 140,00 0,90 126,00 HEPP 7 VOEST ALPINE 187,5 1998 ELIN UNION 16500 140,00 0,90 126,00 HEPP 8 VOEST ALPINE 187,5 1998 ELIN UNION 16500 140,00 0,90 126,00 Action Plan